Piston Crown Bowls Defining Combustion Chamber Constructions In Opposed-Piston Engines
A combustion chamber for an opposed-piston engine is defined between a pair of pistons disposed for opposing reciprocal movement in a cylinder. The combustion chamber is formed between crowns of the pistons and has a radius that decreases from the longitudinal axis of the cylinder. Each crown includes a periphery, a bowl within the periphery defining a concave surface with a first portion curving inwardly toward the interior of the piston and a second portion curving outwardly from the interior, and a convex surface within the periphery curving outwardly and meeting the second portion of the concave surface to form a ridge. Each ridge has a height that decreases with the distance from a longitudinal axis.
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This application is a continuation-in-part of U.S. patent application Ser. No. 13/066,589, filed Apr. 18, 2011, which claims priority to: US provisional application 61/343,308, filed Apr. 27, 2010; U.S. provisional application 61/395,845, filed May 18, 2010; and U.S. provisional application 61/401,598, filed Aug. 16, 2010.
This application is a continuation-in-part of PCT application US2012/038061, filed May 16, 2012, which claims priority to: U.S. provisional application 61/519,194, filed May 18, 2011.
RELATED APPLICATIONSThis application contains material related to that of U.S. patent application Ser. No. 13/136,954, filed Aug. 15, 2011 and published as US 2012/0073541 on Mar. 29, 2012 and U.S. patent application Ser. No. 13/136,955, filed Aug. 15, 2011 and published as US 2012/0073526 on Mar. 29, 2012.
BACKGROUNDThe field is combustion chambers for internal combustion engines. In particular, the field includes constructions for opposed-piston engines in which a combustion chamber is defined between crown bowls of pistons disposed in opposition in the bore of a ported cylinder.
Per
Operation of an opposed-piston engine with one or more ported cylinders (cylinders with one or more of intake and exhaust ports formed therein) such as the cylinder 10 is well understood. In this regard, in response to combustion the opposed pistons move away from respective top dead center (TDC) positions where they are at their innermost positions in the cylinder 10. While moving from TDC, the pistons keep their associated ports closed until they approach respective bottom dead center (BDC) positions where they are at their outermost positions in the cylinder. The pistons may move in phase so that the intake and exhaust ports 14, 16 open and close in unison. Alternatively, one piston may lead the other in phase, in which case the intake and exhaust ports have different opening and closing times. In other configurations, timing offsets can be implemented by placing intake and exhaust ports at different distances from the longitudinal center of the cylinder.
In many opposed-piston constructions, a phase offset is introduced into the piston movements. As shown in
Turbulence is a desirable feature of charge air motion as fuel injection begins. Turbulence encourages the mixing of charge air with fuel for more complete combustion. The geometries of the intake port openings and the cylinder of an opposed-piston engine provide a very effective platform for generation of an appropriate swirling motion of the charge air that promotes both removal of exhaust gasses (scavenging) and charge air turbulence. However, charge air motion that is dominated by swirl can produce undesirable effects during combustion. For example, during combustion in a cylindrical combustion chamber defined between flat piston end surfaces, swirl pushes the flame toward the cylinder bore, causing heat loss to the (relatively) cooler cylinder wall. The higher velocity vectors of swirl occur near the cylinder wall, which provides the worst scenario for heat losses: high temperature gas with high velocity that transfers heat to the cylinder wall and lowers the thermal efficiency of the engine. Accordingly, in such opposed-piston engines, it is desirable to maintain charge air turbulence as injection starts while mitigating the undesirable effects produced by swirl.
In certain opposed-piston combustion chamber constructions, turbulence is produced by squish flow from the periphery of the combustion chamber in a radial direction of the cylinder toward the cylinder's axis. Squish flow is generated by movement of compressed air from a relatively high-pressure region at the peripheries of the piston end surfaces to a lower-pressure region in a bowl formed in at least one piston end surface. Squish flow promotes charge' air turbulence in the combustion chamber. For example, U.S. Pat. No. 6,170,443 discloses a cylinder with a pair of opposed pistons having complementary end surface constructions. A circular concave depression formed in one end surface is symmetrical with respect to the axis of its piston and rises to a plateau in its center. The periphery of the opposing end surface has a convex shape in the center of which a semi-toroidal (half donut-shaped) trench is formed. As the pistons approach TDC, they define a generally toroidally-shaped combustion chamber centered on the longitudinal axis of the cylinder. The combustion chamber is surrounded by a circumferential squish band defined between the concave and convex surface shapes. As the pistons approach TDC, the squish band generates an inwardly-directed squish flow into the toroidal trench and creates “a swirl of high intensity near top dead center.” See the '443 patent at column 19, lines 25-27. Fuel is injected into the toridal combustion chamber in a radial direction of the bore
Increasing the turbulence of charge air in the combustion chamber increases the effectiveness of air/fuel mixing. Domination of charge air motion by swirl or squish flow alone does achieve a certain level of turbulence. Nevertheless, it is desirable to create additional elements of charge air motion as injection commences in order to produce even more turbulence of the charge air, which promotes more uniform mixing than can be obtained with swirl and/or squish, and to mitigate the effects of swirl thereby to reduce the carriage of the heat of combustion to the cylinder wall; one such additional component is tumble. In this regard, tumble is a rotating movement of charge air that circulates in a direction that is transverse to the longitudinal axis of the cylinder. Preferably, the tumbling motion is a circulation of charge air that circulates around a diameter of the cylinder bore.
An exemplary combustion chamber construction for an opposed-piston engine that generates a tumbling component of charge air motion is described and illustrated in US 2011/0271932. The engine includes at least one cylinder with longitudinally-separated exhaust and intake ports, and a pair of pistons disposed in opposition for reciprocating in a bore of the cylinder. As the pistons move toward TDC, a combustion chamber having an elongated ellipsoidal shape is formed in the bore, between the end surfaces of the pistons. The shapes of the end surfaces generate squish flows of charge air having complementary directions that are skewed with respect to a major axis of the combustion chamber. Interaction of the end surface shapes with squish and swirl components of the charge air motion causes generation of one or more tumbling motions in the combustion chamber.
Preferably, the end surface structures of the opposed pistons are identical in shape such that each end surface has a circumferential area centered on the longitudinal axis of the piston, and a bowl within the circumferential area that defines a concave surface with a first portion curving inwardly from a plane containing the circumferential contact area toward the interior of the piston and a second portion curving outwardly from the interior of the piston from the plane containing the circumferential contact area. The pistons are rotationally oriented to place complementary curved surfaces of the bowls in opposition in order to maximize the squish surface areas of the squish zone. These features result in a combustion chamber having the general shape of an elongated ellipsoid.
It has become apparent that a combustion chamber construction for an opposed-piston engine which is specified only as having the general shape of an elongated ellipsoid does not take into account features and dimensions of that “general shape” that can be varied individually, or collectively, in order to increase engine design flexibility and enable achievement of specific goals and requirements for opposed-piston engine performance. Accordingly, there is a need in the field of opposed-piston engine configuration for a systematic volumetric model with which to define combustion chamber constructions by characterization of features and dimensional relationships of combustion chamber elements.
SUMMARYThe three-dimensional shape of the combustion chamber formed between the crowns of two opposed pistons whose end surfaces include bowls has previously been described as ellipsoidal or football-shaped. In this specification, the three-dimensional combustion chamber shape is described in terms of a two-dimensional cross-section that includes shape parameters defining a main volume of the combustion chamber. The main volume of the combustion chamber includes a central region that is closest to the axis of the cylinder which contains the pistons; in some aspects, a portion of the central region is substantially spherical. The two-dimensional cross-section defines a three-dimensional combustion chamber shape that allows the production of tumble due to squish flows directed tangentially to the combustion chamber. Other parallel cross-sections have a similar shape with the exception of a near-injector region where a ridge height approaches zero and a timing edge and squish regions merge to form horizontal squish regions. Desirably, a full three-dimensional piston end surface can be constructed by specifying shape and dimensional parameters of the combustion chamber as a function of the distance along a fuel injection axis.
In the combustion chamber constructions to be described, an internal combustion engine includes at least one cylinder with longitudinally-separated exhaust and intake ports; see, for example, the cylinder 10 illustrated in
During operation of the internal combustion engine, as the pistons approach TDC, squish zones direct flows of compressed air (called “squish flows”) into the combustion chamber in complementary directions that are skewed with respect to a diametrical direction of the bore. This process is referred to as “generating squish”. The portions of the end surfaces that generate squish are referred to as squish surfaces, and channels defined between the squish surfaces are referred to as squish channels. Squish flow is deflected or redirected by one or more curved surfaces in a combustion chamber cavity into at least one tumble motion that circulates in the cavity.
In the following descriptions, “fuel” is any fuel that can be used in an opposed-piston engine. The fuel may be a relatively homogeneous composition, or a blend. For example, the fuel may be diesel fuel or any other fuel ignitable by compression ignition. Further, the descriptions contemplate ignition resulting from compression of an air/fuel mixture; however it may be desirable to provide additional mechanisms, such as glow plugs, to assist compression ignition. The descriptions contemplate injection of fuel into a compressed gas in a combustion chamber. The gas is preferably pressurized ambient air; however, it may include other components such as exhaust gases or other diluents. In any such case, the gas is referred to as “charge air.”
Combustion chamber construction:
The end surface structure of each piston has a periphery surrounding a bowl defining a concave surface. The concave surface includes a first portion curving away from a plane containing the periphery surface toward the interior of the piston and a second portion curving away from the first portion and protruding outwardly in part from the plane. A convex surface opposite the bowl curves away from the periphery and protrudes outwardly from the plane. The convex surface meets the second portion of the concave surface to form a ridge therewith. The end surface structure is provided on both pistons and the pistons are disposed in the bore of a ported cylinder with their end surfaces oriented to place complementary curved surfaces of the end surface structures in opposition in order to define a combustion chamber. The combustion chamber space defined between these two end surfaces has a generally symmetrical geometry to reinforce and sustain tumble motion.
The structures of the piston end surfaces that define the combustion chamber construction are essentially identical to each other; accordingly, the piston 80 shown in
Referring now to
Interactions between the end surfaces 82 and charge air are illustrated and described in related US 2011/0271932. In this regard, squish flows into the combustion chamber affect and are affected by swirl. With regard to
With reference to
In some aspects, it is desirable to inject opposing spray patterns of fuel into the turbulent charge air motion generated in the combustion chamber 100, where the opposing sprays meet in a central region of the combustion chamber and form a cloud of fuel that is well mixed with the compressed charge air due to the turbulence. With reference to
General Combustion Chamber Description: With reference to
The first parameter, RB, has a value corresponding to the distance from the major axis Y of the combustion chamber to the periphery 84, taken along a line segment of a chord of the cylinder bore in which the opposed pistons are disposed for movement. The RB line segment is orthogonal to the major axis Y. RB is a known function of Y since the overall piston must be circular to fit in the cylinder. In those aspects where the periphery 84 is bordered by a flat circumferential area, the second parameter, RT, is measured between the major axis Y and the inner edge 85e of the flat circumferential area. RT is also typically a known function of Y since the flat circumferential area is typically an annular region (with the exception of the near-notch regions), although this is not required. The third parameter, R, is the radius of the main volume of a combustion chamber. A variation of R is typically specified as a function of distance along the major axis Y from the longitudinal center of the cylinder (where Y=0). In some aspects, R varies as a decreasing function of distance from the longitudinal center of the cylinder, which concentrates the combustion volume in the center of the cylinder, near its axis, and reduces heat transfer to the cylinder liner. An unrounded height, H, of the ridge 96 is specified as a function of distance along the major axis Y from the longitudinal center of the cylinder. In some aspects, H is specified as a decreasing function of distance from the longitudinal center of the cylinder. As the value of H decreases at a given cross-section, the lengths of the squish channels 99 decrease, and the cross-section of the combustion chamber becomes less-circular. As the value of H increases towards R, the cross-section of the combustion chamber becomes more circular, but this can create a piston ridge 96 that is difficult to manufacture and cool. These effects can be mitigated through specification of the ridge round radius, RL as a function of distance along the major axis Y from the longitudinal center of the cylinder. In some aspects, RL varies as a changing function of distance along the major axis Y. In this regard, larger RL values at a given cross-section reduce the circularity of the combustion chamber and decrease the length of the squish channels 99. In some crown constructions, RL is applied to a three-dimensional curve at the intersection of a pair of three-dimensional surfaces, resulting in an elliptical round in two-dimensional cross-sections of the crown. However, for simplicity circular rounds are used in the description of the crown shape represented by a sequence of two-dimensional cross-sections.
In the construction illustrated by
Using the parameterized description disclosed and illustrated herein, modifications can be made to bowls formed in the crowns of opposed pistons for the purpose of controlling the distribution of volume within a combustion chamber in an opposed-piston engine. Refer to
With reference to
The combustion chamber constructions described hereinabove are intended to be utilized in opposed-piston compression-ignition engines which impose swirl on the charge of air forced into the cylinder. Nevertheless, the combustion chamber construction can be utilized in those opposed-piston compression-ignition engines that do not swirl the charge air.
The pistons and associated cylinders described herein may be manufactured by casting and/or machining metal materials. For example, the pistons may be constituted of a skirt assembled to a crown on which an end surface with a shaped bowl is formed. As a further example, but without excluding other materials, the crown may comprise a high carbon steel such as 41-40 or 43-40, and the skirt may be formed using 4032-T651 aluminum. In such cases, the cylinder preferably comprises a cast iron composition.
Although an invention has been described with reference to preferred constructions, it should be understood that various modifications can be made without departing from the spirit of the invention. Accordingly, the invention is limited only by the following claims.
Claims
1. An internal combustion engine including at least one cylinder with longitudinally-separated exhaust and intake ports and a pair of pistons disposed in opposition to one another in a bore of the cylinder, in which each piston has a longitudinal axis and a crown with a bowl, and a combustion chamber having a major axis is defined between opposing bowls of the pistons, each crown including:
- a periphery;
- a bowl within the periphery defining a concave surface with a first portion curving inwardly toward the interior of the piston from a plane that is orthogonal to the longitudinal axis of the piston and that contacts the periphery, and a second portion curving outwardly from the interior of the piston through the plane; and,
- a convex surface within the periphery curving outwardly from the plane and meeting the second portion of the concave surface to form a ridge; wherein,
- each ridge has a height H which changes in value from the longitudinal center of the cylinder in a direction along the major axis; and,
- the combustion chamber has a central region with a generally spherical space, with a radius R which changes in value from the longitudinal center of the cylinder in a direction along the major axis.
2. The internal combustion engine of claim 1, in which the opposing pistons are oriented in the bore such that the combustion chamber is defined between the opposing bowls when the pistons are near respective top dead center (TDC) positions in the bore.
3. The internal combustion engine of claim 1, in which injection ports are provided into the combustion chamber at positions on the major axis.
4. The internal combustion engine of claim 1, in which injector ports are provided in the cylinder at positions on the major axis.
5. The internal combustion engine of claim 1, in which the opposing pistons are oriented in the bore such that the convex surface of each crown defines a squish zone with the second portion of the concave surface of the other crown when the pistons are near respective top dead center (TDC) positions in the bore.
6. The internal combustion engine of claim 5, in which opposing concave and convex surface portions in each squish zone cause squish flow into the combustion chamber when the pistons are near respective TDC positions in the bore.
7. The internal combustion engine of claim 6, in which a pair of opposing injector ports is provided through a side of the cylinder, in alignment with the major axis.
8. The internal combustion engine of claim 7, in which each ridge has a rounded configuration having a radius RL.
9. The internal combustion engine of claim 1, in which each ridge.has a rounded configuration having a radius RL which changes in value from the longitudinal center of the cylinder in a direction along the major axis.
10. The internal combustion engine of claim 3, each crown further including a circumferential area extending from the periphery toward the longitudinal axis.
11. The internal combustion engine of claim 10, wherein each circumferential area has a generally annular shape with notches to define the injection ports.
12. A piston having a crown for defining a combustion chamber with the crown of an opposing piston, in which the crown has a periphery centered on the longitudinal axis of the piston; comprising:
- a bowl within the periphery, the bowl defining a concave surface with a first portion curving inwardly toward the interior of the piston from a plane that is orthogonal to the longitudinal axis of the piston and that contacts the periphery, and a second portion curving outwardly from the interior of the piston through the plane; and,
- a convex surface within the periphery curving outwardly from the plane and meeting the second portion of the concave surface to form a ridge; wherein,
- the ridge has a height H that decreases from a maximum at a midpoint of a major axis of the combustion chamber in a direction along the major axis toward the periphery.
13. The piston of claim 12, in which opposing notches are provided in the periphery at respective positions on the major axis of the combustion chamber.
14. The piston of claim 13, in which the ridge has a rounded configuration having a radius RL.
15. The piston of claim 12, in which the ridge has a rounded configuration having a radius RL.
16. The piston of claim 13, further including a circumferential area extending from the periphery toward the longitudinal axis.
17. The piston of claim 16, wherein the circumferential area has a generally annular shape except where the notches are positioned.
18. The piston of claim 17, in which a radius R which changes in value from a central combustion region of the bowl along an axis extending between the notches to reduce volume of the bowl near the notches and a piston cooling gallery extends into an interior portion of the crown between an end surface of the crown and a top land on the crown.
19. An internal combustion engine including at least one cylinder with longitudinally-separated exhaust and intake ports and a pair of pistons disposed in opposition to one another in a bore of the cylinder, in which each piston has a longitudinal axis and a crown with a bowl, and a combustion chamber having a major axis and opposing injector ports aligned on the axis is defined between opposing bowls of the pistons, wherein the combustion chamber includes spherical space centered on the major axis midway between the injector ports and spaces on either side of the spherical space that taper along the major axis Y toward the injector ports.
20. The internal combustion engine of claim 19, in which each crown includes:
- a periphery;
- a bowl within the periphery defining a concave surface with a first portion curving inwardly toward the interior of the piston from a plane that is orthogonal to the longitudinal axis of the piston and that contacts the periphery, and a second portion curving outwardly from the interior of the piston through the plane; and,
- a convex surface within the periphery curving outwardly from the plane and meeting the second portion of the concave surface to form a ridge; wherein,
- each ridge has a height H which decreases in value from the longitudinal center of the cylinder in a direction along the major axis; and,
- the combustion chamber has a central region with a generally spherical space, with a radius R which decreases in value from the longitudinal center of the cylinder in a direction along the major axis.
21. The internal combustion engine of claim 20, in which each ridge has a rounded configuration having a radius RL which changes in value from the longitudinal center of the cylinder in a direction along the major axis.
Type: Application
Filed: Mar 15, 2013
Publication Date: Aug 22, 2013
Patent Grant number: 10180115
Applicant: Achates Power, Inc. (San Diego, CA)
Inventor: Achates Power, Inc.
Application Number: 13/843,686